SHW Group - delivering on a legacy of quality
Since 1954, the SHW Group manufactures brake discs – supplying leading luxury car manufacturers with approximately 4 million brake discs per year.
Balancing lightweight innovation with the stringent quality and durability requirements essential for such a vital safety component, its high-end composite brake discs are under constant review from an in-house R&D team to ensure they deliver in terms of quality and performance.
And in terms of variety. With many of its customers pursuing electrification strategies, SHW Group is also constantly looking for manufacturing options that deliver the type of manufacturing flexibility essential for servicing such a dynamic marketplace.
Dr. Matthias Aust, Plant Manager from SHW Group, said: “Our business model is built on a reputation for quality and attention to detail – it’s the reason high-end automotive manufacturers choose our components over competitors. For us, boosting production capacity and achieving efficiency gains cannot come at the expense of these high standards. Working with ItalPresseGauss means it doesn’t have to. This new line gives us the flexibility and productivity we want, coupled with the quality continuity we need.”
Automated casting designed for diverse requirements
ItalPressGauss’ gravity die casting machines can be supplied as single machines or fully automated solutions in three layouts: carousel, linear cell or flexible cell.
Tailored to exactly match SHW’s layout requirements and working cycles, the new linear casting cell commissioned with ItalPresseGauss comprises gravity die casting machines, furnaces, different ladles, trolleys and process robotics.
From the moment the ring is positioned for pre-heating, every element of the casting process through to final part extraction, transfer and cooling, is completely automated. The solution also supports fully integrated digital tracking for production traceability and quality control.
The new line, which complements two previous gravity die casting carousels supplied by ItalPresseGauss, will allow SHW to produce high quality discs of different weights and metallic composition on the same cell. It also features specially designed robotic grippers that adapt to different component shapes and sizes.
Complex design that makes everything easy
While the line is fully automated, it has also been ergonomically designed to make any human intervention – from system control and maintenance checks to furnace changes – as simple and speedy as possible.
Electrics and energy feeds relating to different cell zones are clearly colour coded, enabling maintenance teams to quickly identify areas that may need attention. All operational and furnace heating controls are also located in a compact area, minimizing unnecessary movement for line management personnel.
Marco Giegold, Area Sales Manager from ItalPresseGauss commented: “We first started working with SHW back in 2016. Since then, our relationship has gone from strength to strength - our engineers and support team working closely with SHW experts to review casting requirements and implement appropriate solutions. We are thrilled that SHW entrust us to keep delivering innovation that allows them to do the same for their customers.”
Foundries interested in the latest die casting, digital and automated cell solutions from ItalPresseGauss will be able to take virtual product tours at this year’s GIFA exhibition (Hall 17, Stand D71). From gravity die casting lines like those used by SHW, to modular Toggle Free HPDC solutions for giant structural casting applications, ItalPresseGauss experts will be available throughout the show to discuss the full range of options available.